Duodos 15, Air-driven double diaphragm pump · 1 Function and Identification 1.1 Function The Duodos is an air-driven double diaphragm pump. The Duodos is run-dry safe and self-priming

Duodos 15Air-driven double diaphragm pump

Assembly and operating instructions

A1263

EN

Original Operating Instructions (2006/42/EC)Part number 985422 BA DUO 008 02/16 EN

Please carefully read these operating instructions before use. · Do not discard.The operator shall be liable for any damage caused by installation or operating errors.

The latest version of the operating instructions are available on our homepage.

In order to make it easier to read, this document uses the maleform in grammatical structures but with an implied neutral sense. Itis aimed equally at both men and women. We kindly ask femalereaders for their understanding in this simplification of the text.

Please read the supplementary information in its entirety.Information

This provides important information relating to the cor‐rect operation of the unit or is intended to make yourwork easier.

Safety InformationThe safety information includes detailed descriptions of the haz‐ardous situation, see Ä Chapter 2.1 ‘Explanation of the safetyinformation’ on page 5The following symbols are used to highlight instructions, links, lists,results and other elements in this document:

More symbols

Symbol Description

Action, step by step

⇨ Outcome of an action

Links to elements or sections of these instructions or other applicable documents

n List without set order

[Button] Display element (e.g. indicators)Operating element (e.g. button, switch)

‘Display /GUI’ Screen elements (e.g. buttons, assignment of function keys)

CODE Presentation of software elements and/or texts

General non-discriminatory approach

Supplementary information

Supplemental instructions

2

Table of contents1 Function and Identification.................................................... 4

1.1 Function........................................................................ 41.2 Identification.................................................................. 4

2 Safety and Responsibility...................................................... 52.1 Explanation of the safety information............................ 52.2 Users' qualifications...................................................... 62.3 Intended use................................................................. 72.4 Duodos general safety notes........................................ 8

3 Transport and storage......................................................... 103.1 Transport.................................................................... 103.2 Storage....................................................................... 10

4 Assembly............................................................................ 114.1 Installation surroundings............................................. 114.1.1 Securing the double diaphragm pump..................... 124.2 Ambient conditions..................................................... 134.3 Layout of the suction side........................................... 134.4 Compressed air supply............................................... 14

5 Operation of the double diaphragm pump.......................... 156 Commissioning................................................................... 16

6.1 Checks prior to commissioning................................... 166.2 Priming........................................................................ 176.3 Interrupting operation.................................................. 17

7 Checking Tightening Torque Prior to Commissioning......... 188 Maintenance of the double diaphragm pump...................... 19

8.1 Troubleshooting.......................................................... 198.2 Air valve maintenance................................................ 218.3 Maintenance of the pilot valve.................................... 238.3.1 Maintenance of the control pins............................... 248.4 Maintenance of the ball valves................................... 258.5 Maintenance of the diaphragms................................. 26

9 Technical Drawing – Duodos 15......................................... 299.1 Exploded drawings and parts lists.............................. 30

10 Spare Parts kits................................................................... 3311 Technical data..................................................................... 34

11.1 Performance curves.................................................. 3512 Disposal of Used Parts....................................................... 3613 Declaration of Conformity................................................... 3714 Index................................................................................... 38

Table of contents

3

1 Function and Identification1.1 Function

The Duodos is an air-driven double diaphragm pump.The Duodos is run-dry safe and self-priming.The pump capacity of the double diaphragm pump can be con‐trolled by changing the pressure in the air supply. The air control isdesigned for oil-free operation. The Duodos is optimally suited tothe transport of liquid chemicals.The Duodos double diaphragm pump transports liquids to a dis‐charge lift of 70 m. As the pump capacity depends greatly on theback pressure, the performance curve must always be observed.At the same time, the differential pressure between the hydraulicand pneumatic sides must not exceed 2 bar. Higher values reducethe service life of the double diaphragm pump.When selecting the double diaphragm pump you must check itsmaterial compatibility. In addition, the density, viscosity, solids con‐tent and temperature of the liquid being transported must be con‐sidered.

Permissible values for the mediumTemperature of the medium– PP version: 5 ... 65 °C– PVDF version: -13 ... 93 °CViscosity of the medium max. 200 mPasSolids content: none

1.2 IdentificationType Housing Diaphragm Feed rate l/h Order number

Duodos 15 PP Santoprene® 0 ... 2000 1010794

Duodos 15 PVDF Teflon® 0 ... 2000 1010798

Function and Identification

4

2 Safety and Responsibility2.1 Explanation of the safety information

These operating instructions provide information on the technicaldata and functions of the product. These operating instructions pro‐vide detailed safety information and are provided as clear step-by-step instructions.The safety information and notes are categorised according to thefollowing scheme. A number of different symbols are used todenote different situations. The symbols shown here serve only asexamples.

DANGER!Nature and source of the dangerConsequence: Fatal or very serious injuries.Measure to be taken to avoid this dangerDanger!– Denotes an immediate threatening danger. If this is

disregarded, it will result in fatal or very seriousinjuries.

WARNING!Nature and source of the dangerPossible consequence: Fatal or very serious injuries.Measure to be taken to avoid this dangerWarning!– Denotes a possibly hazardous situation. If this is

disregarded, it could result in fatal or very seriousinjuries.

CAUTION!Nature and source of the dangerPossible consequence: Slight or minor injuries, mate‐rial damage.Measure to be taken to avoid this dangerCaution!– Denotes a possibly hazardous situation. If this is

disregarded, it could result in slight or minor inju‐ries. May also be used as a warning about materialdamage.

Introduction

Safety and Responsibility

5

NOTICE!Nature and source of the dangerDamage to the product or its surroundingsMeasure to be taken to avoid this dangerNote!– Denotes a possibly damaging situation. If this is

disregarded, the product or an object in its vicinitycould be damaged.

Type of informationHints on use and additional informationSource of the information, additional measuresInformation!– Denotes hints on use and other useful information.

It does not indicate a hazardous or damaging sit‐uation.

2.2 Users' qualifications

WARNING!Danger of injury with inadequately qualified personnel!The operator of the plant / device is responsible forensuring that the qualifications are fulfilled.If inadequately qualified personnel work on the unit orloiter in the hazard zone of the unit, this could result indangers that could cause serious injuries and materialdamage.– All work on the unit should therefore only be con‐

ducted by qualified personnel.– Unqualified personnel should be kept away from

the hazard zone

Training Definition

Instructed personnel An instructed person is deemed to be a person who has been instructed and,if required, trained in the tasks assigned to him/her and possible dangers thatcould result from improper behaviour, as well as having been instructed in therequired protective equipment and protective measures.

Trained user A trained user is a person who fulfils the requirements made of an instructedperson and who has also received additional training specific to the systemfrom ProMinent or another authorised distribution partner.

Trained qualified per‐sonnel

A qualified employee is deemed to be a person who is able to assess thetasks assigned to him and recognize possible hazards based on his/hertraining, knowledge and experience, as well as knowledge of pertinent regula‐tions. The assessment of a person's technical training can also be based onseveral years of work in the relevant field.


6

Training Definition

Electrician Electricians are deemed to be people, who are able to complete work on elec‐trical systems and recognize and avoid possible hazards independently basedon his/her technical training and experience, as well as knowledge of pertinentstandards and regulations.Electricians should be specifically trained for the working environment inwhich the are employed and know the relevant standards and regulations.Electricians must comply with the provisions of the applicable statutory direc‐tives on accident prevention.

Customer Service depart‐ment

Customer Service department refers to service technicians, who havereceived proven training and have been authorised by ProMinent to work onthe system.

Note for the system operatorThe pertinent accident prevention regulations, as wellas all other generally acknowledged safety regulations,must be adhered to!

2.3 Intended use

CAUTION!Intended usePossible consequences if the instructions are notobserved: Minor injuries and material damage– The pump is intended for liquids transport– The pump is not intended for the transport of gas‐

eous or solid media– Only use the pump in accordance with the tech‐

nical data and specifications outlined in the oper‐ating instructions.

– The pump is not designed for use in areas at riskfrom explosion

– Only switch the device on if it has been properlyfastened to the ground or its holding fixture.


7

2.4 Duodos general safety notes

WARNING!Danger from hazardous substances!Possible consequence: Fatal or very serious injuries.Please ensure when handling hazardous substancesthat you have read the latest safety data sheets pro‐vided by the manufacture of the hazardous substance.The actions required are described in the safety datasheet. Check the safety data sheet regularly andreplace, if necessary, as the hazard potential of a sub‐stance can be re-evaluated at any time based on newfindings.The system operator is responsible for ensuring thatthese safety data sheets are available and that theyare kept up to date, as well as for producing an associ‐ated hazard assessment for the workstations affected.

WARNING!Hazardous media / contamination of persons andequipmentPossible consequence: Fatal or very serious injuries.material damage– Ensure the device is resistant to the media being

conveyed– Always observe the safety data sheets for the

media to be conveyed. The system operator mustensure that these safety data sheets are availableand that they are kept up-to-date

– The safety data sheets for the media being con‐veyed are always decisive for initiating countermeasures in the event of leakage to the mediabeing conveyed

– Observe the general restrictions in relation to vis‐cosity limits, chemical resistance and density

WARNING!Service life of the diaphragmPossible consequence: Fatal or very serious injuriesThe service life of the diaphragm cannot be preciselyspecified. For this reason, the possibility of fractureand subsequent leakage of liquids must be taken intoaccount.In addition, you must prevent particles from the defec‐tive diaphragm reaching the media being conveyed.This can be achieved e.g. by filtration, a hose rupturealarm or other means suitable for the respectiveprocess.


8

CAUTION!Compressed airBefore working on the double diaphragm pump, closethe compressed air lines and vent the double dia‐phragm pump.Before undertaking any maintenance and repair work,close off the compressed air supply, discharge thecompressed air and detach the air supply line from thedouble diaphragm pump. The line to the dischargeside of the double diaphragm pump may be underpressure and must likewise be vented.

CAUTION!Hot surfaceWhen conveying hot liquids, the pump can likewisebecome hot. Hot surfaces may then be present on thepump. Bear this in mind and take suitable measures toreduce any hazards.

Maximum pump sound pressure level 91 dBDepending on the operating conditions, the maximumsound pressure level of the device can reach 88 dB ±3 dB. Bear this in mind and take suitable measures toreduce any impact caused by this sound pressurelevel. The type and implementation of suitable meas‐ures depends on the local circumstances and is theresponsibility of the system operator.

Check the fastening elements are correctly seated.Before commissioning the double diaphragm pump,you must check that all fastening elements with sealingrings are correctly seated. The seals may ‘creep’ , sothat the fastening elements come loose over time.

In the event of a diaphragm ruptureIn the event of a diaphragm rupture, the pumpedmedium can enter the air system of the double dia‐phragm pump and from there into the atmosphere. Ifthe pumped medium is a dangerous, harmful or toxicsubstance, the air outlet must be routed to a suitablearea where safe disposal is possible.

Operation in the open air and outdoors– Take suitable measures to protect the device from

environmental influences when operating outsidesuch as:– UV rays– Humidity– Frost, etc.


9

3 Transport and storagen User qualification, transport and storage: trained user, seeÄ Chapter 2.2 ‘Users' qualifications’ on page 6


3.1 TransportTransportn The pump is protected by means of cardboard packagingn The packaging materials can be recycledn Consider the ambient conditions

3.2 StorageThe device must be completely drained before storage.

Permissible storage conditions:

All versions: + 5 °C ... 60 °C

All versions: < 95% relative air humidity (non-condensing)

Permissible operating conditions:

All versions: - 10 °C ... 40 °C

All versions: < 95% relative air humidity (non-condensing)

Transport and storage

10

4 Assemblyn User qualification, installation: trained qualified personnel, seeÄ Chapter 2.2 ‘Users' qualifications’ on page 6

CAUTION!Possible consequence: Slight or minor injuries. Mate‐rial damage.Observe the permissible ambient conditions.

4.1 Installation surroundings

Upright installationInstall the double diaphragm pump upright and plumb.The valves of the double diaphragm pump operatewhen loaded by gravity. The valve balls are pressed bygravity into the valve seat and seal it off. Installationoutside the vertical axis impairs the function of thevalves.

Nominal width of the pipeworkThe threaded connectors must not reduce the nominalwidth of the pipework or the double diaphragm pump.The hydraulic connectors have internal and externalthreads. Do not screw threaded fittings on to theinternal thread as this would lead to a reduction of thenominal width.

Keep the suction line short and the number of pipe valves small.Do not reduce the diameter of the suction line. If a rigid pipeworksystem is used, short flexible hose pieces should be insertedbetween the double diaphragm pump and pipework to protect thedouble diaphragm pump against vibration and tensile and com‐pressive forces. The installation of a pulsation damper is recom‐mended to reduce pulsations in the pumped medium.

Assembly

11

A1142

1.

2. 3. 4. 5. 6.

7.

8. 9. 10. 11. 12.

13.

14. 16. 17. 18.

19.

15.

Fig. 1: Installation surroundings1. Pulsation damper2. Flexible connection3. Pipe connection4. Manometer5. Shut-off valve6. Discharge side7. Outlet valve8. Flexible connection9. Filter/controller module10. Air dryer (option)

11. Shut-off valve12. Compressed air connection13. Outlet valve14. Suction side15. Shut-off valve16. Manometer17. Pipe connection18. Flexible connection19. Air outlet

4.1.1 Securing the double diaphragm pump

Correct securing of the deviceOnly switch the device on if it has been properly fas‐tened to the ground or its holding fixture. The systemoperator is responsible for ensuring that the groundand the fittings can hold the device safely and under alloperating conditions.

Assembly

12

4.2 Ambient conditions

NOTICE!Ambient conditionsPossible consequence: Property damage andincreased wear and tearAssembly is to be carried out in the following order. Ifthe pump has to be installed outdoors, then it is to beequipped with protection against sunlight and weatherinfluences.When positioning the pump, ensure that sufficientroom for access is provided for all types of mainte‐nance work.

4.3 Layout of the suction side

Nominal width of the pipeworkThe threaded connectors must not reduce the nominalwidth of the pipework or the double diaphragm pump.The hydraulic connectors have internal and externalthreads. Do not screw threaded fittings on to theinternal thread as this would lead to a reduction of thenominal width.

Dimensioning of the suction sideLayout the suction side with generous dimensions. Thesupply of the double diaphragm pump with the liquid tobe pumped must be ensured under all load and oper‐ating statutes. Ensure that the inside diameters of thesuction lines are generously sized.

To ensure a maximum service life of the diaphragm, the doublediaphragm pump should be installed as close as possible to thepumped medium. If there is a positive priming pressure on the suc‐tion side of more than 3.0 m water column, the fitting of a backpressure valve in the air outlet of the double diaphragm pump isrecommended in order to protect the diaphragm. The minimum airpressure to operate the double diaphragm pump is approximately 1bar.

Assembly

13

4.4 Compressed air supply

Compressed air supplyThe double diaphragm pump must be connected to acompressed air supply in accordance with the currentstate of the art (ISO 8573-1). We require unoiled,residual oil-free (residual oil from the compressors ofmaximum 0.1 mg/m³ for HEES-liquids, bio-oils or max.5mg/m³ permitted for mineral oils) and appropriatelydried compressed air (ISO 8573-1, class 4 with 3 °CPDP).Our recommendation is that the pressure dew pointmust be at least 10 °C below the ambient temperature.

Suitable compressed air supplyThe system operator is responsible for the provision ofa suitable compressed air supply. In doing so, observeISO 8573.

Layout the compressed air supply with generous dimensions. Yourcompressed air supply must be able to supply the double dia‐phragm pump with sufficient compressed air at any time and underall operating statutes. In this respect also consider the air con‐sumption of other devices and machinery connected to the samecompressed air supply. Considerable pressure fluctuations canoccur in the compressed air supply when switching compressed airconsumers on and off.The air pressure of the supplied air must not exceed 7 bar (100psi). Connect the air inlet of the double diaphragm pump to a com‐pressed air supply, which is designed to provide the required pumpcapacity in terms of air quantity and pressure. To guarantee thesupply pressure remains within the specified values, a controlvalve should be connected upstream of the double diaphragmpump.In there is a rigid air supply line insert a short piece of flexible hosebetween the double diaphragm pump and the pipework.The weight of the air supply line, control valve, and filters must notweigh upon the air connection fitting of the double diaphragmpump, rather it must be supported in a suitable manner. Otherwisethe double diaphragm pump can be damaged.

Based on their design, the air valve and the pilot valve do notrequire any lubrication and indeed must not be lubricated.

Water in the compressed air can lead to the exhaust air freezing orthe double diaphragm pump icing up. The possible consequencesare malfunctions or failure of the double diaphragm pump. It is rec‐ommended that an air dryer is fitted. This extracts the water fromthe compressed air and protects against icing up.

Lubrication of the air valves

Moisture in the air line

Assembly

14

5 Operation of the double diaphragm pumpn User qualification: operation instructed personnel, seeÄ Chapter 2.2 ‘Users' qualifications’ on page 6

The double diaphragm pump is fully integrated into the customerprovided system and is then controlled from this system. It is notpossible to operate the double diaphragm pump directly.

Operation of the double diaphragm pump

15

6 Commissioningn User qualification, commissioning: trained user, see Ä Chapter

2.2 ‘Users' qualifications’ on page 6

Check the fastening elements are correctly seated.Before commissioning the double diaphragm pump,you must check that all fastening elements with sealingrings are correctly seated. The seals may ‘creep’ , sothat the fastening elements come loose over time.

6.1 Checks prior to commissioning


The following checks are to be carried out:n Ensure that the device has not been damaged during transpor‐

tation or storage. Immediately report any damage to the sup‐plier

n Check that the air pressure is suitable for the device.n Ensure that the device is suitable for the liquid to be conveyed

and that it will not be attacked.n Make sure that the temperature of the liquid does not exceed

the recommended temperature rangen Install a manometer in the discharge line if the back pressure

value is unknownn Under the operating conditions, check the values for flow, pres‐

sure, etc.n Install a pressure relief valve in the discharge line in order to

protect the pump in the event that a valve is unintentionallyclosed off or the line is blocked in another way.

Commissioning

16

6.2 Priming1. To start the double diaphragm pump, open the air value by

approximately 1/2 to 3/4 of a turn2.

CavitationIf opening of the air valve causes the stroke rateof the double diaphragm pump to increase, butnot however the flow volume passing through thedouble diaphragm pump, then cavitation is thecause. Slightly turn back the air valve so that theair consumption and feed rate of the double dia‐phragm pump are set in an optimum ratio.

Once the double diaphragm pump is filled with water, openthe air valve further to set the required air flow.

6.3 Interrupting operation


Rinse through the double diaphragm pump after every use if liquidsare used which when stationary have a tendency to form depositsor to solidify. This avoids damage to the double diaphragm pump.Liquid residues remaining in the double diaphragm pump may dryout and form deposits. When restarting the double diaphragmpump, this can lead to problems at the diaphragms and the ballvalves. At temperatures below 0 °C the double diaphragm pumpmust always be completely drained.

Commissioning

17

7 Checking Tightening Torque Prior to Commissioning

Lasting tightnessCheck that the threaded connectors have the correcttorque during commissioning.We also recommend checking these threaded connec‐tors for correct torque at least once a year because thepump material yields and the tightening torque is thenreduced.

A2250

8,0 Nm 8,0 Nm

8,0 Nm

8,0 Nm

Fig. 2: Checking tightening torque prior to commissioning.1. Tighten all screws (9) to 8.0 Nm.2. Tighten all screws (10) to 8.0 Nm.3. Tighten all screws (12) to 8.0 Nm.4. Tighten all screws (14) to 8.0 Nm.

Checking Tightening Torque Prior to Commissioning

18

8 Maintenance of the double diaphragm pumpn User qualification, Maintenance: instructed personnel, seeÄ Chapter 2.2 ‘Users' qualifications’ on page 6


Before all workBefore all work on the double diaphragm pump, dis‐connect the double diaphragm pump from the com‐pressed air supply and the feed and discharge lines,vent and decontaminate. Always observe the safetydata sheet for the chemicals to be conveyed.

8.1 TroubleshootingPossible symptomsn Double diaphragm pump does not cyclen Double diaphragm pump cycles, but does not pumpn Double diaphragm pump cycles, but insufficient feed raten Double diaphragm pump cycles irregularlyn Double diaphragm pump vibrates strongly

Cause: Measure:

Suction lift of the system too high For suction lifts above 6 metres, priming of the pump can in mostcases be induced by pre-filling the pump chambers

Too high priming pressure on thesuction side of the system

If there is a priming pressure of more than 3 metres water column, pro‐vide a back pressure valve in the air outlet of the double diaphragmpump

Back pressure of the mediumhigher than the air pressure

Increase the air inlet pressure to the double diaphragm pump

Compressed air pressure higherthan the back pressure of themedium

Adjust the feed air pressure according to the performance curve of thedouble diaphragm pump. At high stroke rates, cavitation in the mediummay occur

Suction line of too small nominalwidth

Observe the recommendations of the dimensioned drawing for thecross-section of the suction line

Maintenance of the double diaphragm pump

19

Cause: Measure:

Air line of too small nominal width Observe the recommendations for dimensioning of the air inlet line inthe operating instructions of the double diaphragm pump

Air distribution system of thedouble diaphragm pump

Dismantle and examine the air valve, pilot valve and control pins

Rigid pipe connections at thepump

Use flexible connections and a pulsation damper

Exhaust air silencer blocked Remove the silencer. Then clean or de-ice and refit.

Pumped medium in the exhaustair silencer

Dismantle pump chambers and determine whether a diaphragm isbroken or a diaphragm flange is loose

Ball valve blocked Dismantle the liquid end of the double diaphragm pump and clear theblockage

Ball valve or valve seat worn ordistorted

Check the ball valves and valve seats for wear and correct seatingReplace as necessary

Suction line blocked Clear blockage or check and clean suction line

Discharge line blocked Check for blockage. Valves in the discharge line may be closed

Pump chamber blocked Dismantle the liquid end and inspect the diaphragm chambers of thedouble diaphragm pump


20

8.2 Air valve maintenance

To carry out maintenance on the air valve, first discon‐nect the compressed air supply, vent the double dia‐phragm pump and remove the air supply line from thedouble diaphragm pump.

A1148

Fig. 3: Air valve maintenance1. Remove the 4 screws (1J)2. Remove the cover (1I)3. Remove the silencer (1H)

ð Check the silencer and replace as necessary.

4. Using pliers, remove the two covers (1E) of the air valve

ð Replace the parts (1C and 1F) as necessary.

5. Pull the piston (1B) out of the control cylinder. Ensure thatthe piston is not scratched or damaged

6. Clean the piston with a soft cloth7. Check the piston for scratches and signs of wear

ð Replace the piston as necessary.

8. Check whether the control cylinder (one part of 1B) is dirty onthe inside or scratched

ð Replace the control cylinder and piston (1B) as neces‐sary.

9. Insert the cover (1E) with the parts (1C and 1F) into the airvalve housing (1A)

10. Remove the new control cylinder and piston (1B) from theplastic bag and pull the piston out of the control cylinder

Dismantling the air valve

Reassembling the air valve


21

11. Push the six O-rings (1C) onto the control cylinder and pressthe O-rings into the recesses

12. Coat the O-rings thinly with grease prior to fitting the controlcylinder in the air valve housing

13. Align the slots in the control cylinder with the slots in the airvalve housing (1A)

14. Push the piston into the control cylinder up to the end coveralready fitted. Ensure that this does not cause any scratches.

15. Fit the second end stop complete with an O-ring16. Fit the remaining safety collar17. Now you can refit the air valve housing in the pump18. Use the four hexagonal head screws to replace the cover (1I)

and the silencer (1H) on the double diaphragm pump.19. Tighten the four hexagonal head screws to 3.4 Nm20. Switch the compressed air supply back on

ð The double diaphragm pump is now ready for use.


22

8.3 Maintenance of the pilot valve

To carry out maintenance on the pilot valve, first dis‐connect the compressed air supply, vent the doublediaphragm pump and remove the air supply line fromthe double diaphragm pump.

A1149

Fig. 4: Maintenance of the pilot valve1. Remove the 4 hexagonal head screws2. Remove the air inlet cover3. Remove the seal

ð Check the seal and replace as necessary.

You can now remove the pilot valve.4. Remove the pilot valve piston (3D) and the O-rings5. Clean all parts with a soft cloth6. Check all parts for scratches and signs of wear and tear

ð Replace the parts as necessary.

7. Remove the safety collar from the end of the control cylinder8. Clean all parts with a soft cloth9. Check all parts for scratches and signs of wear and tear

ð Replace the parts as necessary.

10. Thinly apply grease to the outside of the control cylinder andthe O-rings

11.Do not squeeze the O-rings when doing so.

Insert the control cylinder into the valve housing12. Insert the safety collars into the control cylinder

Dismantling the pilot valve

Reassembling the pilot valve


23

13. Thinly apply grease to the control piston and O-rings14. Insert the control piston into the control cylinder15. Place the seal on the pilot valve housing16. Carefully insert the pilot valve into the recess on the pump

housing17. The control pins must align correctly with the pilot valve con‐

trol piston18. Fit the seal, the air inlet cover and the hexagonal screws19. Switch the compressed air supply back on

ð The double diaphragm pump is now ready for use.

8.3.1 Maintenance of the control pins

For maintenance, first interrupt the supply of com‐pressed air, bleed the double diaphragm pump andremove the air supply line from the double diaphragmpump.

31

31

7

4

7

27

27

3030

A1150

Fig. 5: Maintenance of the control pins1. Use a screwdriver to remove the two safety collars (31) to

maintain the control pin components.

ð We would recommend using new safety collars whenreassembling.

2. Remove both guide sleeves (7)3. Check the guide sleeves for wear and scratches and replace

as necessary4. Check both O-rings (27) for wear and scratches and replace

as necessary5. Refit all components

Insert the pilot valve into the pumphousing


24

8.4 Maintenance of the ball valves

An inspection or maintenance is normally indicated ifupon starting the double diaphragm pump:– primes badly– provides less capacity– cycles irregularly– cycles, but does not pump

1. First close the suction line of the double diaphragm pump2. Close the discharge line of the double diaphragm pump3. Shut-off the compressed air supply4. Vent the double diaphragm pump5. Remove the air supply line from the double diaphragm pump6. If necessary remove any liquid which may remain in the

double diaphragm pump

ð Now the double diaphragm pump can be removed formaintenance.

35

2

26

15

19

10

9

A1151

Fig. 6: Maintenance of the ball valves1. Remove the elbow (19) to gain access to the ball valves2. Check the valve balls (2) for wear, abrasion and scratches3. Examine the outer and inner edges of ball valve seats (35)

for scratches, abrasion and material that has eaten into thesurface

ð It is important that the curve of the balls aligns perfectlywith the profile of the bevelled edges for the seal to sitcorrectly. Replace worn or damaged parts.

4. Insert the valve seat (3) into the pumping housing

Before maintenance work

Reassemble the ball valve


25

5. Place a valve ball (2) on the valve seat and screw the pipeelbow (19) to the pumping housing

1. Attach the air supply line to the double diaphragm pump2. Open the compressed air supply3. Open the discharge line of the double diaphragm pump4. Open the suction line of the double diaphragm pump

ð Now the double diaphragm pump can pump again

Check all connectors for leak-tightness

8.5 Maintenance of the diaphragms1. First close the suction line of the double diaphragm pump2. Close the discharge line of the double diaphragm pump3. Shut-off the compressed air supply4. Vent the double diaphragm pump5. Remove the air supply line from the double diaphragm pump6. If necessary remove any liquid which may remain in the

double diaphragm pump

ð Now the double diaphragm pump can be removed formaintenance.

326

29

2016 28

1511

14 20

16

28

1514

26

11

A1152

Fig. 7: Maintenance of the diaphragms1. Unscrew the 16 screws that fasten the pipe elbow to the

pumping housings

ð Remove the brackets including the associated distributorfittings.

After maintenance work

Before maintenance work

Duodos PP


26

2. Unscrew the 16 screws (11 and 14) that hold together thepumping housing, the diaphragms and the pump housing.

3. Remove the diaphragm assembly (consisting of the outerdiaphragm flange, the diaphragms and inner diaphragmflange) in a counterclockwise direction from the piston rod(32)

4. Screw an adjustment screw into the threaded opening of theinner diaphragm flange (29)

5. Clamp the projecting bolt and the adjustment screw looselyinto a vice

6. Remove the outer diaphragm flange (28) in a counterclock‐wise direction

7. Examine the diaphragm (20) for scratches, tiny holes andwear. Examine the diaphragms for signs that the diaphragmshave been attacked by the pump medium

ð Use new diaphragms as necessary.

8. Insert the threaded bolt of the outer diaphragm flange thoughthe hole into the centre of the diaphragm

9. Screw the inner diaphragm flange clockwise onto thethreaded bolt

10. Clamp the loosely assembled group with the adjustmentscrew used above into a vice

11. Tighten the loosely assembled group using a 10 Nm torquewrench

ð Wait a minimum of 15 minutes until the components havesettled and repeat the tightening procedure to 10 Nm.

13. Tighten the outer diaphragm flange to approx. 3 Nm. The dia‐phragm must not turn freely with the diaphragm flange whentightening.

14. Check that the shock absorber (6) is attached to the pistonrod

15. Screw the threaded bolt of one of the diaphragm assembliesclockwise into the threaded hole at the end of the piston roduntil the end of the piston rod is aligned correctly with theinner diaphragm flange.

16. Insert the piston rod into the pump17. Align the screw holes in the diaphragm with the screw holes

in the pump housing18. Screw the pumping housing (15) with the screws (11 and 14)

and the nuts to the pump housing, at the same time pullingout the piston rod on the opposite side of the pump as far aspossible

19. Check that the shock absorber (6) is attached to the pistonrodScrew the threaded bolt of the second diaphragm assemblyclockwise into the threaded hole at the end of the piston rod(32) just far enough to align the screw holes in the diaphragmto the holes in the pump housing

20. Fit the diaphragms, as shown in the cross-section, with thefolds pointing to the centre of the pump

21. Fix the second outer chamber to the pump housing with thescrews and the nuts

Removing the liquid ends.

Removing and dismantling the dia‐phragm assembly.

Assembling the diaphragm assembly.

Fitting the liquid end.


27

22. Screw the angle fitting including the distributor using thescrews and nuts

ð The pump can now be reinstalled, connected to the com‐pressed air supply and started up.

1. Attach the air supply line to the double diaphragm pump2. Open the compressed air supply3. Open the discharge line of the double diaphragm pump4. Open the suction line of the double diaphragm pump

ð Now the double diaphragm pump can pump again

Check all connectors for leak-tightness

326

29

1617 28

1511

26

11

14

1617

28

1514

A1153

Fig. 8: Maintenance of the overlay diaphragms - Duodos PVDF16. Santoprene® diaphragm17. PTFE overlay diaphragm

The PTFE overlay diaphragm (17) lies tightly on the outside of thenormal Santoprene® membrane (16). Remove and fit as describedfor standard diaphragms.

After maintenance work

Maintenance of the overlay dia‐phragms - Duodos PVDF


28

9 Technical Drawing – Duodos 15

143

92

287

243

140 35

4476

179

103

258

129

4852

104

200

166

Ø8

2

I. II.

III.IV.

A1154

Fig. 9: Technical Drawing – Duodos 15 / All dimensions in "mm"I. Connector rotatable by ± 90°II. Compressed air connector 1/4" NPT

III. Suction connection, external thread, 1" BSPIV. Discharge connector, external thread, 1" BSP

Technical Drawing – Duodos 15

29

9.1 Exploded drawings and parts lists

A1155

Fig. 10: Exploded drawing – Duodos 15

Exploded drawing – Duodos 15


30

Parts list Duodos 15 PP

Item Quantity Article no. Description Material

1 1 031-116-000 Air valve, complete Sub-assembly

2 4 050-027-354 Valve ball Santoprene®

3 1 095-091-000 Pilot valve, complete Sub-assembly

4 1 114-023-551 Pump housing Polypropylene, fibreglass-reinforced

5 2 115-140-115 Assembly bracket Stainless steel 302/304

6 2 132-034-360 Shock absorber, piston rod Buna-N®

7 2 135-036-506 Guide sleeve Delrin®

8 1 165-110-551 Cover, air inlet Polypropylene, fibreglass-reinforced

9 12 171-062-115 Hexagonal head screw 5/16-18 x 1.00 Stainless steel 302/304





15 2 196-178-552 Pumping housing Polypropylene

16 2 286-095-354 Diaphragm Santoprene®

18 2 312-106-552 Pipe elbow, suction side Polypropylene

19 2 312-112-552 Pipe elbow, discharge side Polypropylene

20 2 360-099-360 Seal, diaphragm Buna-N®

21 1 360-100-360 Seal, air inlet Buna-N®

22 1 360-101-360 Seal, pilot valve Buna-N®

23 1 360-102-360 Seal, air valve Buna-N®

24 2 518-138-552 Distributor fitting Polypropylene

26 36 544-005-115 Flange nut 5/16-18 Stainless steel 302/304

27 2 560-001-360 O-ring Buna-N®

28 2 612-091-552 Outer diaphragm flange Polypropylene

29 2 612-177-330 Inner diaphragm flange Steel, galvanized

30 2 620-019-115 Control pin Stainless steel 302/304

31 2 675-042-115 Safety collar Stainless steel 302/304

32 1 685-056-120 Diaphragm piston rod Stainless steel 416

33 2 720-012-360 Seal, piston rod Buna-N®

34 4 720-045-600 Seal, distributor fitting PTFE

35 4 722-099-600 Valve seat PTFE


31

Parts list – Duodos 15 PVDF


1 1 031-116-000 Air valve, complete Sub-assembly

2 4 050-022-600 Valve ball PTFE


4 1 114-023-551 Pump housing Polypropylene, fibre‐glass-reinforced

5 2 115-140-115 Assembly bracket Stainless steel 302/304



8 1 165-110-551 Cover, air inlet Polypropylene, fibre‐glass-reinforced






15 2 196-178-520 Pumping housing PVDF


17 2 286-096-600 Overlay diaphragms PTFE

18 2 312-106-520 Pipe elbow, suction side PVDF

19 2 312-112-520 Pipe elbow, discharge side PVDF




24 2 518-138-520 Distributor fitting PVDF

26 36 544-005-115 Flange nut 5/16-18 Stainless steel 302/304

27 2 560-001-360 O-ring Buna-N®

28 2 612-091-520 Outer diaphragm flange PVDF

29 2 612-177-330 Inner diaphragm flange Steel, galvanized



32 1 685-056-120 Diaphragm piston rod Stainless steel 416





32

10 Spare Parts kitsSpare parts kit Part no.

Spare parts kit for air drive for Duodos 15 1010811

Spare parts kit for liquid end for Duodos 15 PP 1010802

Spare parts kit for liquid end for Duodos 15 PVDF 1010807

Spare parts kit for air drive - Duodos 15 (order no. 1010811):

Item Quan‐tity

Article no. Description Remark

1 1 031-166-000 Control cylinder and piston Sub-assembly







27 2 560-001-360 O-ring Buna-N®




Spare parts kit for liquid end for Duodos 15 PP (order no. 1010802):


2 4 050-027-354 Valve ball Santoprene®


20 2 360-099-360 Seal, diaphragm Buna-N®



Spare parts kit for liquid end for Duodos 15 PVDF (order no. 1010807):


2 4 050-022-600 Valve ball PTFE


17 2 286-096-600 Overlay diaphragms PTFE



Parts list for spare parts kit - Duodos15

Spare Parts kits

33

11 Technical dataTechnical data – Duodos 15 PP/PVDF

Part no. 1010794 1010798

Pump type Duodos 15 PP Duodos 15 PVDF

Pump capacity (max.) 2000 l/h 2000 l/h

Back pressure (max.) 70 m water column 70 m water column

Feed rate/stroke 0.098 l 0.098 l

Temperature of medium 5 ... 65 °C -13 ... 93 °C

Suction lift moist 8.2 m 8.2 m

Suction connector 1" BSP external 1" BSP external

Discharge connector 1" BSP external 1" BSP external

Compressed air con‐nector

1/4" NPT internal 1/4" NPT internal

Air consumption 3.5 ... 27 Nm3/h 3.5 ... 27 Nm3/h

Max. air pressure 7 bar 7 bar

Minimum air pressureapprox.

1 bar 1 bar

Pumping housing PP PVDF

Diaphragm Santoprene® Santoprene®

Overlay diaphragms None PTFE

Valve balls Santoprene® PTFE

Valve seats PTFE PTFE

Seals PTFE PTFE

Pump housing Polypropylene, fibreglass-rein‐forced

Polypropylene, fibreglass-reinforced

Assembly bracket Stainless steel 302/304 Stainless steel 302/304

Weight 8 kg 9 kg

Dimensions L x W x H 258 x 179 x 287 mm 258 x 179 x 287 mm

Material Min. op. temperature Max. op. temperature

Santoprene® -23 °C 100 °C

Thermoplastic elastomers produced in the injection moulding process without a mesh layer. Flexible withhigh durability. Excellent abrasion hardness.

PTFE -37 °C 100 °C

Chemically inactive and effectively impermeable. Only a very few chemicals are know to react with Teflon®.

PVDF -13 °C 93 °C

Polypropylene 5 °C 65 °C

Operating temperatures

Technical data

34

Tool Size (mm) Duodos 15

3/16" Allen key 4.76 mm x

1/4" Allen key 6.35 mm

Spanner 3/8" 9.52 mm x

Spanner 7/16" 11.11 mm


Spanner 9/16" 14.28 mm


Spanner 1 3/8" 34.92 mm

Screw driver 7 mm 7.00 mm

11.1 Performance curves

Performance curvesThe performance curves are based on the pumping ofwater at ambient temperature (approx. 20 °C).

I.

II.

III.

20 PSI (1,36 bar) Air Inlet Pressure

40 PSI (2,72 bar)

60 PSI (4,08 bar)

80 PSI (5,44 bar)

100 PSI (6,8 bar)

A1159

600 1200 1800 2400 3000 3600(l/h)

Fig. 11: Performance curves – Duodos 15I. Back pressure in barII. Pump capacity in l/hIII. Air consumption in m3/h

Repair tools

Technical data

35

12 Disposal of Used Partsn User qualification: instructed user, see Ä Chapter 2.2 ‘Users'

qualifications’ on page 6

NOTICE!Regulations governing the disposal of used parts– Note the current national regulations and legal

standards which apply in your country

The manufacturer will take back decontaminated used units pro‐viding they are covered by adequate postage.Decontaminate the unit before returning it for repair. To do so,remove all traces of hazardous substances. Refer to the MaterialSafety Data Sheet for your feed chemical.A current Declaration of Decontamination is available to downloadon the ProMinent website.

Disposal of Used Parts

36

13 Declaration of ConformityIn accordance with DIRECTIVE 2006/42/EC OF THE EUROPEANPARLIAMENT AND OF THE COUNCIL, Appendix I, BASICHEALTH AND SAFETY REQUIREMENTS, section 1.7.4.2. C.We,n ProMinent GmbHn Im Schuhmachergewann 5 - 11n D - 69123 Heidelberg, Germany,hereby declare that the product specified in the following, complieswith the relevant basic health and safety requirements of the ECDirective, on the basis of its functional concept and design and inthe version distributed by us. Any modification to the product notapproved by us will invalidate this declaration.

Extract from the EC Declaration of Conformity

Designation of the product: Pneumatic double diaphragm pump

Product type: Duodos

Serial number: see nameplate on the device

Relevant EC directives: EC Machinery Directive (2006/42/EC)

Harmonised standards applied,in particular:

EN ISO 12100 / 2010EN 809

Date: 01.03.2012

The EC Declaration of Conformity is available to download on ourhomepage.

Declaration of Conformity

37

14 IndexAAction, step by step . . . . . . . . . . . . . . . . . . . . . . . . 2Air consumption in m3/h . . . . . . . . . . . . . . . . . . . 35Applied harmonised standards . . . . . . . . . . . . . . 37Assembling the diaphragm assembly. . . . . . . . . . 26

BBack pressure in bar . . . . . . . . . . . . . . . . . . . . . . 35

CCorrect and proper use . . . . . . . . . . . . . . . . . . . . . 7Counter measures . . . . . . . . . . . . . . . . . . . . . . . . . 8

DDesignation of the product . . . . . . . . . . . . . . . . . 37

FFitting the liquid end. . . . . . . . . . . . . . . . . . . . . . . 26

GGeneral non-discriminatory approach . . . . . . . . . . 2

LLinks to elements or sections of these instruc‐tions or other applicable documents . . . . . . . . . . . 2

MMaintenance of the overlay diaphragms -Duodos PVDF . . . . . . . . . . . . . . . . . . . . . . . . . . . 28More symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

NNon-discriminatory approach . . . . . . . . . . . . . . . . 2

OOperation in the open air and outdoors . . . . . . . . . 9

PProtection against sunlight . . . . . . . . . . . . . . . . . 13Protection against the weather . . . . . . . . . . . . . . 13Pump capacity in l/h . . . . . . . . . . . . . . . . . . . . . . 35

QQuestion: What type of tools do I need forrepairs? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

RRelevant EC directives . . . . . . . . . . . . . . . . . . . . 37Removing and dismantling the diaphragmassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Removing the liquid ends. . . . . . . . . . . . . . . . . . . 26Repair tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SSafety data sheet . . . . . . . . . . . . . . . . . . . . . . 8, 10Safety information . . . . . . . . . . . . . . . . . . . . . . . . . 5Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

UUsers' qualifications . . . . . . . . . . . . . . . . . . . . . . . 6

Index

38

39

985422, 2, en_GB

© 2016

ProMinent GmbHIm Schuhmachergewann 5 - 1169123 Heidelberg, GermanyTelephone: +49 6221 842-0Fax: +49 6221 842-419Email: [email protected]: www.prominent.com

Documents

Duodos 15, Air-driven double diaphragm pump · 1 Function and Identification 1.1 Function The Duodos is an air-driven double diaphragm pump. The Duodos is run-dry safe and self-priming